Claims:We claim:
1. A polymer-based composition for producing a lightweight component for automobiles, said composition comprising polypropylene copolymer;
fibrous magnesium hydroxide sulfate hydrate; and reinforcement material comprising glass fibres.
2. The polymer-based composition as claimed in claim 1, wherein said polypropylene copolymer is present in an amount ranging from 70 wt% to 80 wt% of the total composition.
3. The polymer-based composition as claimed in claim 1, wherein said fibrous magnesium hydroxide sulfate hydrate is present in an amount ranging from 2 wt % to 8 wt% of the total composition.
4. The polymer-based composition as claimed in claim 1, wherein said glass fibre is present in an amount ranging from 15 % to 22 % by weight of the total composition.
5. The polymer-based composition as claimed in claim 1, wherein said glass fibre reinforcement material is present in an amount ranging from 18 % to 22 % by weight of the total composition.
6. The polymer-based composition as claimed in claim 1, wherein ratio of said magnesium hydroxide sulfate hydrate fibrous filler and reinforcing material is in the range of 1:1.5 to 1:4.
7. The polymer-based composition as claimed in claim 1, wherein said polypropylene copolymer is compounded with said fibrous magnesium hydroxide sulfate hydrate and reinforcement material.
8. The polymer-based composition as claimed in claim 1, wherein said composition has a melt flow index in the range of 10 to 15g/10 mins.
9. The polymer-based composition as claimed in claim 1, wherein said composition has a melt flow index is 12 g/10 mins.
10. The polymer-based composition as claimed in claim 1, wherein density of said composition is in the range of 1.05 to 1.10 gm /cc.
11. The polymer-based composition as claimed in claim 1, wherein density of said composition is 1.09 gm /cc.
12. The polymer-based composition as claimed in claim 1, wherein said composition has a tensile strength in the range of 55 to 65 Mpa.
13. The polymer-based composition as claimed in claim 1, wherein heat deflection temperature is in the range of 158 to 165 degree Celsius.
14. The polymer-based composition as claimed in claim 1, wherein Notched Izod Impact strength of said composition at 23 degrees Celsius temperature is in the range of 10 to 15 kJ/m2; and -30 degrees Celsius temperature is a value greater or equal to 4 kJ/m2.
15. The polymer-based composition as claimed in claim 1, wherein flexural modulus of said composition is in the range of 4000 to 4500 Mpa.
16. The polymer-based composition as claimed in claim 1, wherein elongation at yield of said composition is in the range of 6 to 6.5%.
17. The polymer-based composition as claimed in claim 1, wherein said lightweight component is an engine cover.
18. A lightweight component for an automobile, comprising the polymer-based composition claimed in claim 1.
19. An engine cover for automobiles, comprising the polymer-based composition claimed in claim 1.
20. An engine cover for automobiles, obtained by molding the composition claimed in claim 1.
21. A method for producing an engine cover, said method comprising molding the composition claimed in claim 1 to obtain an engine cover.
22. The method as claimed in claim 1, wherein said molding is performed by injection molding.
, Description:TECHNICAL FIELD
[001] The present invention relates to polymer composition, and more particularly to polymer compositions for producing lightweight components of automobiles.
BACKGROUND
[002] Over the past 20 years, the automobile industry has been under constant innovation. Rising demands to improve fuel economy drives the need for automotive engineers to find lighter, better-performing material for hotter, smaller engines and lighter power trains. The latest development in the automobile industry, however, is to hide the inner workings of engine compartments by installing covers to engines for a cleaner look. Engine covers, once considered a luxury commodity, are now becoming more common in economy vehicles. Engine cover, apart from adding to the aesthetic appeal of an engine, also functions to suppress the emission of noise from the engine. Engine covers can be of metal or plastic. Plastic engine covers are preferred to metal engine covers as they are lightweight, have relatively higher heat resistance, and can absorb vibrations, dampening the sound of the engine. According to industry estimates, a weight reduction of up to 50% can be achieved with plastic for metal substitutions.
[003] Plastics, attributing to its lightweight and ease in handling, are generally most preferable for engine covers. The selection of polymer material used to manufacture the engine covers is crucial. Materials selected are required to have good mechanical properties such as heat resistance, good fluidity to ensure workability, and remain lightweight. Traditional examples include polyphthalamide (PPA), a semi-aromatic polyamide, etc. The current industry standard includes materials such as reinforced plastics. A common material that is used to create engine covers is Polyamide (Nylon 66). Despite it having favourable properties such as high abrasion resistance, good thermal resistance, good fatigue resistance, high machinability, and noise dampening, they are also susceptible to water damage, as they are slightly hygroscopic. Polyamides also possess lower resistance to strong acids and bases, and high percentages of shrinkage.
[004] Polypropylene is a thermoplastic polymer, produced via chain growth polymerization. It is an economical material that offers a combination of advantageous physical, mechanical and thermal properties. They are of two basic types: Polypropylene Homopolymer (PPH) with a high strength to weight ratio and good chemical resistance and weldability, and Polypropylene copolymer (PPC) with improved impact strength, tougher, more durable surface properties, and better crack resistance. Despite its various favourable properties and superior working temperature and tensile strength, polypropylene copolymers on their own have lower impact strength, leaving considerable room for improvement.
[005] As described, currently, there are materials available in the market that are either lightweight or are heat resistant. However, there is a lack of material that can satisfy all mechanical properties, such as lower weight, high temperature resistance, low cost and higher impact strength as is required for an effective engine cover. Hence, there exists a need for a cheap, lightweight material with dimensional stability under high temperature such as engine thermal conditions.
OBJECTS OF THE DISCLOSED EMBODIMENTS
[006] The principal object of the embodiments disclosed herein is to provide a polymer-based composition for lightweight components.
[007] A second object of the embodiments disclosed herein is to provide a polymer-based composition for automobile engine covers.
[008] Another object of the embodiments disclosed herein is to provide engine covers having improved dimensional stability, especially under engine thermal conditions.
[009] Further an object of the embodiments disclosed herein is to provide lightweight components for automobiles.
[0010] An object of the embodiments disclosed herein is to provide engine covers having improved structural and thermal barrier properties.
[0011] Another object of the embodiments disclosed herein is to provide a method and composition for producing engine covers having improved productivity requiring lower cycle time and lesser material consumption.
[0012] Another object of the embodiments disclosed herein is to provide recyclable engine covers.
[0013] Yet another object of the embodiments disclosed herein is to provide an improved method for producing recyclable engine covers.
[0014] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying tables and figures. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include such modifications.
BRIEF DESCRIPTION OF FIGURES
[0015] The embodiments disclosed herein are illustrated in the accompanying drawings. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0016] Fig. 1 is a graphical representation of difference in density of conventional polyamide-based composition and a composition according to the embodiments herein. 
DETAILED DESCRIPTION
[0017] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as not to unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0018] The embodiments herein disclose a polymer-based composition for use in automobiles. The polymer-based composition, according to embodiments herein may be used to produce lightweight components in automobiles including, but not limited to, engine hood, engine covers, engine oil sumps, engine under cover, engine rear and front covers, radiator support, etc. In an embodiment, the polymer-based composition is used to produce engine covers, particularly front and/or rear covers. Accordingly, embodiments herein disclose a lightweight engine cover having improved dimensional stability. The embodiments herein achieve a lightweight component for automobiles having improved structural and functional properties such as thermal stability, structural barrier and torque criteria. The embodiments herein achieve engine covers having potential weight reduction of about 20% as compared to that of conventional polyamide-based engine covers. The considerable reduction in weight may be attributed to the optimized flow behaviour, tensile strength, modulus and impact strength, of the composition. Further, the embodiments herein are suitable and adaptable to existing mold and molding processes requiring reduced consumption of material. The embodiments of the lightweight components disclosed herein, are further capable of being recycled completely and used for other similar application at low or no additional costs. Therefore, embodiments herein achieve cost effective, eco-friendly lightweight components having improved dimensional stability.
Polymer-based composition
[0019] Embodiments herein include a polymer-based composition for producing lightweight components of automobiles. The embodiments herein disclose a polypropylene based composition. The composition, according to embodiments herein, includes compounded polypropylene homo or copolymers comprising fibrous magnesium hydroxide sulfate hydrate and reinforcing material. In an embodiment, the composition comprises polypropylene copolymers, fibrous magnesium hydroxide sulfate hydrate and reinforcing material comprising glass fibres.
[0020] Polypropylene, particularly polypropylene copolymer (PPCP) forms a major portion of the polymer-based composition, according to embodiments herein. Alternatively, polypropylene homopolymers, preferably including impact modifiers may also be used I some embodiments of the composition. The quantity of PPCP in the composition may vary from 70 to 85 wt% of the total composition. In an embodiment, the composition includes PPCP in the range of 70 to 80 wt%, or 71 to 79 wt% of the total composition. In other embodiments, the amount of polypropylene copolymer is 70 wt%, 71 wt%, 72 wt%, 73 wt%, 74 wt%, 75 wt%, 76 wt%, 77 wt%, 78 wt%, 79 wt%, or 80 wt% of the total composition.
[0021] The polypropylene copolymer, according to embodiments herein, includes any copolymer comprising propylene and other monomer. The other monomer, as referred to herein, includes any monomer, or monomer combinations, capable of copolymerizing with propylene such as, but not limited to, ethane, ethylene, diene monomers, α-olefins, cyclic olefins, etc. Examples of such monomers include, but is not limited to, ethylene, butene, isobutene, pentene, hexene, octene, decene, or derivatives thereof such as acyclic and cyclic derivatives, or combination thereof, such as 2-methyl-1-pentene, 2,3-dimethyl-1-pentene, 4-methyl-1-pentene, 2-methyl-1-butene, cyclopentene, cyclobutene, cyclobutadiene, dicyclopentadiene, hexadiene, etc. The polypropylene copolymer may include propylene and other monomer at suitable proportions or concentrations. For example, the copolymer may comprise about 45 to 95% of propylene content while the other monomer content may vary from 55% to 5% of the total copolymer. In an embodiment, the copolymer includes about 45%, 55%, 65%, 75%, 80%, 85%, or 90% of propylene content. Further, the polypropylene copolymer may be block copolymers, alternate copolymers, random copolymers, and/or graft copolymers, or combinations thereof. In an embodiment, the polypropylene copolymer is a block copolymer. In a specific embodiment, the polypropylene copolymer is a block copolymer of propylene and ethylene. In another embodiment, the polypropylene copolymer is a random copolymer. In a specific embodiment, the polypropylene copolymer is a random copolymer of propylene and ethylene. Alternatively, various commercially available polypropylene copolymer may be used, examples include trade names such as Repol D120MA and Repol MI3530.
[0022] The polypropylene copolymer, according to embodiments herein, may be produced by methods generally known in the art. In some embodiments, the copolymers include Atactic, Isotactic and/or Syndiotactic copolymers.
[0023] The embodiments of composition, as disclosed herein, further include magnesium hydroxide sulfate hydrate. Magnesium hydroxide sulfate hydrate, according to embodiments herein, refers to a compound having a chemical formula of H2MgO5S. The composition, as disclosed herein, may comprise magnesium hydroxide sulfate hydrate in any suitable form including, but not limited to, fibrous form; powder; whiskers; nanoribbons; nanobelts; or tetrahedra, octahedral, or spiral structures; or combinations thereof. In an embodiment, the composition comprises fibrous magnesium hydroxide sulfate hydrate. Further, in some embodiments, the composition may further include other mangnesium sulfate crystal whisker such as magnesium oxysulfate whiskers, magnesium hydroxide oxysulfate hydrate whiskers, etc.
[0024] The quantity of magnesium hydroxide sulfate hydrate in the polymer-based composition may vary from 2 wt% to 8 wt% of the total composition. In an embodiment, the composition includes magnesium hydroxide sulfate hydrate in the range of 2 to 8 wt%, or 3 to 7 wt% of the total composition. In other embodiments, the amount of fibrous magnesium hydroxide sulfate hydrate is 3 wt%, 4 wt%, 5 wt%, 6 wt%, or 7 wt% of the total composition.
[0025] The embodiments of composition, as disclosed herein, is further reinforced by inclusion of reinforcing material. In an embodiment, the reinforcing material includes glass fibres. The glass fibres may be used as long continuous filaments of glass, short or chopped fibres or ground fibres, or in any other suitable form. Various types of glass fibres are generally known based on the nature and type of dopants, raw materials, etc. Glass fibres may generally include ingredients such as boron trioxide, alumina, zinc oxide, titanium dioxide, zirconium dioxide, flor, sodium oxide, barium oxide, etc. Examples include, but is not limited to, A type, C type, D type, E type, ECR glass, AR type, R type, S-2 type of glass fibre. The fibre diameter generally is in the range of 7 to 18 μm, preferably about of 9 to 15 μm. In an embodiment, the glass fibre is E type glass fibre. Any suitable type and dimension of glass fibres may be used in various embodiments herein. The glass fibres, according to embodiments herein, may further be functionalized or modified to improve its reinforcing properties for eg: with silane modifiers. Various such glass fibres are commercially available which may be used, examples include trade names such as P968 of Vetrotex or CS147 (R34BX1) of OCF.
[0026] The amount of glass fibres in the polymer-based composition may vary from 15 wt% to 22 wt% of the total composition. In an embodiment, the composition includes glass fibres in the range of 15 to 22 wt%, or 18 to 22 wt% of the total composition. In other embodiments, the amount of glass fibres is 15 wt%, 16 wt%, 17 wt%, 18 wt%, 19 wt%, 20 wt%, 21 wt% or 22 wt% of the total composition. The ratio of magnesium hydroxide sulfate hydrate fibrous filler and glass fibres may suitably vary. In an embodiment of the invention, the ratio of magnesium hydroxide sulfate hydrate fibrous filler to glass fibres in the composition is in the range of 1:1.5 to 1:4. In an embodiment of the invention, the ratio is 1:2.5, 1:3, or 1:3.5.
[0027] While the preferable reinforcing material is glass fibres, other suitable reinforcing material may optionally be used. Other suitable reinforcing material may be a suitable amount of other material selected from generally known filler material such as quartz, carbon fibres, silica, talc, glass beads, chalk, feldspar, titanium dioxide, etc. It is understood that various modifications and alterations to the material and composition would be apparent to a person skilled in the art, in light and, within the spirit and scope of the disclosure made herein.
[0028] The composition may further include other additives such as nucleating agents, antistatic agents, antioxidants, stabilizers, colouring agents, viscosity modifiers, slip or mold release agents, coupling agents, etc. Such additives are typically included in an amount of about 2 wt% each, or less, of the total composition. In an embodiment, the composition includes the additive in an amount of 2 wt % of the total composition.
[0029] The various ingredients or components, according to embodiments herein, may be mixed, blended and/or kneaded by methods and equipments generally known in the art. A homogenous or heterogenous blend of the composition is prepared by mechanically blending the individual components using conventional compounding processes. In an embodiment, the polypropylene copolymer is compounded with the other components such as magnesium hydroxide sulfate hydrate and glass fibres, either individually or simultaneously.
[0030] The compounded polypropylene copolymer may then be extruder, and/or molded to obtain lightweight component, such as engine covers, of suitable shape and size. Conventional equipments include kneader mixing roll, stirring blade, screw extruder, etc. Conventional molding processes and manufacturing techniques may be used to obtain the desired lightweight components, eg: engine covers. Example of such molding processes include blow molding, injection molding, casting rotational molding, compression molding, etc. In preferred embodiments, injection molding processes are used. Conventional injection molding processes may be used, examples include metal injection molding, overmolding, insert molding, gas-assisted injection molding, thin wall molding, thermoplastic injection molding, liquid silicone injection molding, hot runner molding, etc. In an embodiment, the method for producing the engine cover comprises molding the disclosed polymer-based composition to obtain an engine cover. In a preferred embodiment, the molding is performed by injection molding.
[0031] The composition, according to embodiments disclosed herein, is such that it achieves improved productivity in molding processes as it requires less material consumption and cycle time. Further, the composition’s adaptability to conventional molding or manufacturing processes enables production at low or no additional cost with no requirement of new manufacturing process and equipments. A considerable reduction, potentially up to about 45% relatively, in manufacturing costs may be achieved by embodiments herein.
[0032] Embodiments herein include lightweight components, particularly for automobiles. The term, “lightweight component”, as used herein includes any polymer-based component, article, or parts thereof, particularly in automobiles, expected or required to have dimensional stability or thermal stability. Examples include engine accessories including but not limited to, engine hoods, engine covers, engine oil sumps, engine under cover, etc. It refers to any automobile component which is likely to be exposed to higher temperatures. In an embodiment, the lightweight component is engine covers or hoods, such as front and rear covers, or parts thereof. In some embodiments, the lightweight component is a part or portion of engine covers or hoods. While embodiments herein are preferably directed towards engine accessories and engine covers, the composition may very well be adapted or employed in other automotive structures such as radiator support, engine mounting systems, water tank assembly, chassis components, fire wall, pedals, pedal blocks, gear-shift blocks, dashboard support, seat and floor reinforcement systems, other internal fittings, exhaust systems, or parts thereof, etc.
[0033] The engine cover, according to embodiments herein, may be of any suitable size, shape or design. Engine covers generally have a thickness of about 2.5 mm or less. Embodiments herein are not limited to size, shape or design and may be suited to reduce weight and/ or improve aesthetics. In an embodiment, the average thickness of engine cover is in the range of 1.2 to 2.5mm, preferably 1.5 to 1.8 mm. In an embodiment, the average thickness is about 1.5mm.
[0034] The invention is further described by reference to the following examples by way of illustration only and should not be construed to limit the scope of the embodiments disclosed herein. It will be apparent to those skilled in the art that many modifications, both to materials and methods, may be practiced without departing from the scope of the claimed embodiments.
[0035] Exemplary embodiments of the composition, according to embodiments herein, and its constituents are depicted in the following examples.
Example 1
[0036] Table 1: List of ingredients in sample composition 1.
No. Ingredients Sample 1
1 PPCP 71 wt %
2 Magnesium hydroxide sulfate hydrate 7 wt%
3 Glass fibre 22 wt%

Example 2
[0037] Table 2: List of ingredients in sample composition 2.
No. Ingredients Sample 2
1 PPCP 73 wt %
2 Magnesium hydroxide sulfate hydrate 6 wt%
3 Glass fibre 21 wt%

Example 3
[0038] Table 3: List of ingredients in sample composition 3
No. Ingredients Sample 3
1 PPCP 71 wt %
2 Magnesium hydroxide sulfate hydrate 7 wt%
3 Glass fibre 22 wt%

Example 4
[0039] Table 4: List of ingredients in sample composition 4.
No. Ingredients Sample 4
1 PPCP 74 wt %
2 Magnesium hydroxide sulfate hydrate 5 wt%
3 Glass fibre 21 wt%

Example 5
[0040] Table 5: List of ingredients in sample composition 5.
No. Ingredients Sample 5
1 PPCP 76 wt %
2 Magnesium hydroxide sulfate hydrate 5 wt%
3 Glass fibre 19 wt%

Example 6
[0041] Table 6: List of ingredients in sample composition 6
No. Ingredients Sample 6
1 PPCP 76 wt %
2 Magnesium hydroxide sulfate hydrate 6 wt%
3 Glass fibre 18 wt%

Example 7
[0042] Table 7: List of ingredients in sample composition 7.
No. Ingredients Sample 7
1 PPCP 75 wt %
2 Magnesium hydroxide sulfate hydrate 5 wt%
3 Glass fibre 20 wt%

Example 8
[0043] Table 8: List of ingredients in sample composition 8.
No. Ingredients Sample 8
1 PPCP 78 wt %
2 Magnesium hydroxide sulfate hydrate 3 wt%
3 Glass fibre 19 wt%

Example 9
[0044] Table 9: List of ingredients in sample composition 9

No. Ingredients Sample 9
1 PPCP 79 wt %
2 Magnesium hydroxide sulfate hydrate 4 wt%
3 Glass fibre 18 wt%

Example 10
[0045] Table 10: List of ingredients in sample composition 10.
No. Ingredients Sample 10
1 PPCP 77 wt%
2 Magnesium hydroxide sulfate hydrate 4 wt%
3 Glass fibre 19 wt%

Example 11
[0046] Table 11: List of ingredients in sample composition 11.
No. Ingredients Sample 11
1 PPCP 72 wt%
2 Magnesium hydroxide sulfate hydrate 6 wt%
3 Glass fibre 22 wt%

[0047] The embodiments herein were further tested on various parameters such as long term heat aging test, hot/cold cycling test, humidity ageing, chemical resistance, cold impact, vehicle level test and structural durability test. It was observed that abnormalities like crack, deformation, softening, warpage, visual discoloration and loosening in the front / rear engine cover, were absent. The long term heat and humidity aging tests was performed at 100 °C for 500 hours and 40±2 °C at 95±5% relative humidity for 168 hours, respectively. No cracks were found in any of the points on front / rear engine cover made from the present polymer-based composition when subjected to cold impact test, performed at -30 °C for 5 hours. It was further observed that, after completion of 100 cycles no cracks were seen on front / rear dust cover made. Embodiments herein were further subjected to structural durability CAE analysis and it was observed that stress versus deflection were well within the limit.
[0048] Comparative study of the present composition with various combination and other polyamide-based composition was performed. Group 1 to Group 5 depict various combinations of compositions and its constituents. Group 1 compositions are sample compositions having about 68 to 72 wt % of Polyamide/ Nylon and about 28 to 32 wt % of glass fibres. Group 2 compositions are sample compositions having about 76 to 84 wt % of PPCP, 8 to 12 wt% of Magnesium hydroxide sulfate hydrate and 8 to 12 wt % of talc. Group 3 compositions are sample compositions having about 76 to 84 wt % of PPCP, 8 to 12 wt% of Magnesium hydroxide sulfate hydrate and 8 to 12 wt % of glass fibres. Group 4 compositions are sample compositions having about 71 to 79 wt % of PPCP, 8 to 12 wt% of Magnesium hydroxide sulfate hydrate and 13 to 17 wt % of glass fibres. Group 5 compositions are sample compositions having about 71 to 79 wt % of PPCP, 3 to 7 wt% of Magnesium hydroxide sulfate hydrate and 18 to 22 wt % of glass fibres. Table 12 depicts the compositions, and its constituents, used for the analysis.
[0049] The compositions were tested for physical, mechanical, thermal and weathering properties such as balanced flow, tensile strength, modulus, impact strength, and thermal properties. Melt flow index or melt flow rate (MFI or MFR) was determined by ASTM D1238, Density was determined by ASTM D792, Tensile strength was determined by ASTM D638, Elongation at yield was determined by ASTM D638, Flexural modulus was determined by ASTM D790, Notched izod impact strength at 23°C was determined by ASTM D256, Notched izod impact strength at -30°C was determined by ASTM D256, and Heat deflection temperature (HDT) was determined by ASTM D648. Table 13 depicts the results and properties of the compositions.
[0050] The MFI, or melt flow index, is a measure of the ease of flow of the melt of a thermoplastic polymer. It is generally defined as the weight of a polymer in grams flowing in 10 min through a die of specific diameter and length by a pressure applied by a given weight at a given temperature. In the study, it is observed that group 2 showed MFI of about 10 to 15 g/10min, while group 5 showed 12 g/min. Fig. 1 is a graphical representation of the difference in density of a group 1 sample composition and a group 5 sample composition; wherein sample 1 includes 70 wt % of Polyamide/ Nylon and 30 wt % of glass fibres; and sample 5 includes 75 wt % of PPCP, 5 wt% of fibrous magnesium hydroxide sulfate hydrate and 20 wt % of glass fibres. As depicted in Fig. 1, the density of sample 5 is lesser and more suitable as compared to that of a polyamide based composition, sample 1. Tensile strength or maximum load that a material can support without fracture when being stretched, divided by the original cross-sectional area of the material, of each polymer composition or group of compositions was tested. Group 1 showed tensile strength of about 120 Mpa while Group 5 showed tensile strength of 62 Mp. Group 5 also showed a maximum elongation at yield, of 6.3 %. The notched Izod impact tests at both 23 degree Celsius and at -30 degree Celsius were performed. Notched Izod Impact test is a single point test that measures a materials resistance to impact from a swinging pendulum. Izod impact is defined as the kinetic energy needed to initiate fracture and continue the fracture until the specimen is broken. Notched Izod impact tests at both 23 degree Celsius and -30 degree Celsius of Group 5 was 14 kJ/m2 and >4 kJ/m2, respectively.
[0051] Table 12: Compositions/Groups used for comparative analysis.
Component Group 1 Group 2 Group 3 Group 4 Gorup 5
PA6 (Polyamide/ Nylon) 68 – 72 wt % 0 wt % 0 wt % 0 wt % 0 wt %
PPCP (Propylene compounded copolymer) 0 wt % 76 – 84 wt % 76 – 84 wt % 71 – 79 wt % 71 – 79 wt %
Magnesium hydroxide sulfate hydrate filler 0 wt % 8 – 12 wt % 8 – 12 wt % 8 – 12 wt % 3 – 7 wt %
Glass fibre 28 – 32 wt % 0 wt % 8 – 12 wt % 13 – 17 wt % 18 – 22 wt %
Talc 0 wt % 8 – 12 wt % 0 wt % 0 wt % 0 wt %

[0052] Table 13: Physical, mechanical, thermal and weathering properties.
Properties Standard Units Group 1 Group 2 Group 3 Group 4 Group 5
MFI ASTM D1238 g/10min NA 10 – 15 13 9 12
Density ASTM D792 gm /cc 1.36 1.05 1.05 1.09 1.09
Tensile strength ASTM D638 Mpa 120 23 45 54 62
Elongation at yield ASTM D638 % NA 2.4 5.2 5..9 6.3
Flexural modulus ASTM D790 Mpa 6000 3000 3250 3500 4200
Notched izod impact strength at 23°C ASTM D256 kJ/m2 20 13 8 11 14
Notched izod impact strength at -30°C ASTM D256 kJ/m2 10 3 - 4 3 - 4 >4 >4
HDT ASTM D648 ° C 220 129 158 160 161

[0053] Accordingly, disclosed are embodiments having melt flow index in the range of 10 to 15g/10 mins. In an embodiment, the composition has MFI in the range of 10 to 15g/10 mins, preferably 12 g/10 mins. In a specific embodiment, the composition has MFI of 12 g/10 mins.
[0054] Also disclosed are embodiments having density in the range of 1.05 to 1.12 gm /cc, preferably 1.07 to 1.10 gm /cc. In an embodiment, density of the composition is 1.09 gm /cc. Embodiments disclosed herein have tensile strength in the range of 55 to 65 Mpa, preferably 60 to 62 Mpa. In an embodiment herein, tensile strength of the composition is 62 Mpa. Further, disclosed are embodiments having a heat deflection temperature is in the range of 158 to 165 degree Celsius, preferably 160 to 162 degree Celsius. In an embodiment, HDT of the composition is 161 degree Celsius.
[0055] Also, disclosed are embodiments having Notched Izod Impact strength at 23 degrees Celsius temperature in the range of 10 to 16 kJ/m2, preferably 11 to 15 kJ/m2 or 13 to 14 kJ/m2; and at -30 degrees Celsius temperature is a value greater or equal to 4 kJ/m2. In an embodiment, the composition has notched izod impact strength at 23 degrees Celsius temperature of 14 kJ/m2. In an embodiment, the composition has notched izod impact strength at -30 degrees Celsius temperature is greater than 4 kJ/m2 (i.e >4 kJ/m2).
[0056] Flexural modulus, of various embodiments herein may be in the range of 4000 to 4500 Mpa, preferably 4100 to 4300 Mpa. In an embodiment, the composition has flexural modulus of 4200 Mpa. Elongation at yield of the embodiments disclosed herein may be in the range of 6 to 6.5%. In an embodiment, elongation at yield is about 6.3%.
[0057] Embodiments herein are recyclable, stable, non-hazardous, and capable of cross deployment to similar application at low or no costs, making it eco-friendly and highly efficient. Further, the articles, particularly engine covers, manufactured from the disclosed embodiments of aid in reducing total vehicular weight, by up to 20% reduction; and manufacturing costs, by up to 45%, as compared to that manufactured with conventional materials such as metal (aluminium, steel, etc) or other polymers such as polyamide.
[0058] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.